Eaton UltraShift Plus

Eaton Hybrid Electrical

Eaton Hybrid Hydraulic

A rich history of Fuller Automation Experience

1985 1989 1991

2001

2003 2004

1993

2005 2006 2010

1994

1998 1999 2000

AutoShift 10

AMT CEEMAT

AutoSelect

AutoShift 16

AutoShift 18 AutoShift 6 UltraShift HP

UltraShift LST

2002

1997

UltraShift HV UltraShift LHP UltraShift Plus

Eaton AMT Roadmap Explained

AutoShift (3-pedal)

AS-10 AutoShift 10-Speed (RT-10B/C)

AS-18 AutoShift 18-Speed (RT-18A)

UltraShift (2-pedal, DM Clutch)

LST Line Haul Standard (RT-10B)

LHP Line Haul Performance (RT-13A)

LEP Line Haul Efficient Performance (RT-13A)

UltraShift Plus (2-pedal, ECA)

MHP Multipurpose High Performance (RTLO-13B)

MXP Multipurpose Xtreme Performance (RTLO-18B)

VXP Vocational Xtreme Performance (RTLO-18B)

VCS Vocational Construction Series (RTO-8LL)

VMS Vocational Multipurpose Series (RTO-9ALL)

LAS Line Haul Active Shifting (RTO-10B/C)

Feb2007

Eaton UltraShift Plus

New Linehaul Models

OverdriveFO-14/16/18E310C-LAS

FOM-14/15/16E310C-LAS

Direct-Drive

FM-14/15E310B-LAS

M = Multi-torque,

+200 lb ft in top 2 gears

UltraShift M Series

Two automated transmission models have been

developed for Highway / Multipurpose Applications

UltraShiftMXPMultipurpose Extreme

Performance

UltraShift MHPMultipurpose Highway

Performance

FO- 14/16/18/20/E313A-MHP

Overall ration coverage of 17:1FO-14/16/18/20/22/E318B-MXP

Overall ratio coverage of 20:1

Ratings up to 2250lbft

UltraShift V Series

UltraShift VXPVocational Extreme

Performance

On/Off Highway

UltraShift VCSVocational

Construction

Series

UltraShift VMSVocational

Multipurpose

Series

Three automated transmission models have been

developed for Vocational Applications

FO-14/16/18/20/22/E318B-VXP

Overall ratio coverage of 20:1

Ratings up to 2250lbft

High Performance/

Steep Grades/Heavy Loads

FO- 14/16/E308LL-VCS

Overall ratio coverage of 20:1

(with Wide Reverse Ratios)

Dump Truck/Roll-Off Refuse

FO- 14/16/E309ALL-VMS

Overall ration coverage of 36:1

Front or Rear Discharge Mixer

NomenclatureUltraShift Vocational Construction Series (VCS) – sharing ratios with an 8LL FO-14E308LL-VCS

FO-16E308LL-VCS

UltraShift Vocational Multipurpose Series (VMS) – sharing ratios with a 9ALL FO-14E309ALL-VMS

FO-16E309ALL-VMS

UltraShift Vocational Extreme Performance (VXP) – sharing ratios with an 18B FO-14E318B-VXP

FO-16E318B-VXP

FO-18E318B-VXP

FO-20E318B-VXP

FO-22E318B-VXP

UltraShift Multipurpose Extreme Performance (MXP) – sharing ratios with an 18B FO-14E318B-MXP

FO-16E318B-MXP

FO-18E318B-MXP

FO-20E318B-MXP

FO-22E318B-MXP

UltraShift Multipurpose High Performance (MHP) – sharing ratios with a 13 FO-14E313B-MHP

FO-16E313B-MHP

FO-18E313B-MHP

FO-20E313B-MHP

Safety

Hill Start Aid

Auto Neutral

Auto-engage on downgrades

Creep mode

No urge to move

Fuel Savings

All the benefits of a manual

transmission plus…

ECA Technology

Maximum Grade to

Launch and Shift:

What is ECA?

Electronic Clutch ActuationUsing electronics vs. electro-pneumatic or

mechanical to manage clutch engagement

and disengagement improves transmission

performance in a number of areas:

• Clutch engagement and consequential shifts are rapid – ECA

facilitates superior transmission performance in on-highway

environments

• Enables technologies such grade sensing, weight computation

and driver throttle commands to allow the transmission to make

intelligent shift decisions to meet performance, reliability & safety

requirements

ECA Design – LCIBLow Capacity Inertia Brake

Coaxial about the Transmission Input Shaft

No Additional Exterior Space Claim

2500 rpm/sec decal rate

Strap-drive IP

Solo

adjustment

system

Backer plate

to actuate

LCIB

Sealed release

bearing

ECA-Clutch Design (15.5”, 2 plate, ceramic)

Vehicle Installation / Integration

Installation - Same

as G3 UltraShift

Except:

• Solo-Clutch

• ECA space-claim

• Oil-fill Site-glass

• Engine Speed

Sensor

• Grade Sensor

• Overall length

• 4-Chl ABS with

ATC & HSA

What a Fleet wants…

Maneuverability

Warranty

Skip Shifting

Intelligent Shifting

Fuel Saving

Engine Braking

Creep Mode

Hill Start Aid

Auto Neutral

Ease of Operation

Meeting & Exceeding Customer Expectations

Driveline Protection

Driveline Protection Features

Stall prevention

Engine Over-speed Protection

Clutch Abuse Protection

Auto gear select

Skip shifting where appropriate

Safety

Creep

feature

(no “urge to

move”)Hill Start Aid

Auto

Engage

on down

grades

Auto

Neutral

Serviceability & Repairability

Many similar components between manual platforms,

other Ultrashift platforms:

OEM dealer, fleet familiarity

Parts and service widely available

Does not require service by a dedicated service network

Modular design minimizes cost and time of service

Roadranger field service force provides training at

dealership and fleet level

Advanced Gen 3 diagnostic capabilities

© 2002 Eaton Corporation. All rights reserved.

Eaton Hybrid Electric System Overview

“What is HYBRID?”(EATON HYBRID TECHNOLOGY – NO COMPROMISE)

Traditional Drivetrain

ENGINE

HPT

kW+

Motor/Generator

Tengine

hp

kWkW

kW+

Hybrid Drivetrain

Same Vehicle

Torque

Output

History

In 1899 Dr Ferdinand Porsche,

then a young engineer at Jacob

Lohner & Co, built the first Hybrid

Vehicle

Hybrid Definition: "A vehicle with more than one power source

such as a small internal combustion engine and an electric motor”

Data Source: www.hybrid-vehicle.org

Eaton HEV History & Progress

City Delivery HEV System Diagram

Utility HEV System Diagram

Primary Hybrid Components

Power Electronics

Carrier (Battery Box)

DC/DC Converter

Motor

Inverter/Controller Hybrid Drive Unit

(HDU)

Fuller Automated

Transmission (AMT)

120VAC/60Hz Power Panel

Auxiliary Power Generator (AGP)

Inverter

DC/DC Converter

Motor Controller/Inverter

Hybrid Electric Motor

Electric Clutch

Power Electronics Carrier (PEC)

Lithium Ion Batteries and

Battery Controls

Engine Start (Start-Stop) Mode

Direct Hybrid - Engine Starting Mode

Engine

(on)

Motor

(on)

AutoShift (AMT)

(in neutral)

Battery System

(discharging mode)

AutoClutch

(engaged)

Inverter & Power Panel

(off)

PTO

Pump

(off)

Utility Tools

(off)

Engine

Torque

Discharging

Mode

Driving ---- Electric only (EV) mode

Engine

(Idle)

Motor

(on)

AutoShift (AMT)

(in gear)

Battery System

(discharging mode)

AutoClutch

(disengaged)

Motor

Torque

Drive

Torque

Direct Hybrid - Electric Only Mode

Drive Trq = Motor

Trq x Gear Ratio

Inverter & Power Panel

(off)

PTO

Pump

(off)

Utility Tools

(off)

Driving ---- Parallel Hybrid (motor boost)

Mode

Drive Trq = (Engine

Trq + Motor Trq ) x

Gear Ratio

Direct Hybrid - Engine & Electric Motor Drive Mode

Engine

(on)

Motor

(on)

AutoShift (AMT)

(in gear)

Battery System

(discharging mode)

AutoClutch

(engaged)

Drive

Torque

Inverter & Power Panel

(off)

PTO

Pump

(off)

Utility Tools

(off)

Engine

Torque

Combined

Torque

Driving ---- Conventional (back-up) Mode

Direct Hybrid - Engine Only Mode

Engine

(on)

Motor

(on/off optional)

AutoShift (AMT)

(in gear)

Battery System

(charging mode optional)

AutoClutch

(engaged)

Drive

Torque

Trq = Engine Trq

x Gear Ratio

Inverter & Power Panel

(off)

PTO

Pump

(off)

Utility Tools

(off)

Engine

Torque

Engine

Torque

Driving ---Maximum Regenerative Braking Mode

Utility Tools

(off)

Engine

(on)

Motor

(on)

AutoShift (AMT)

(in gear)

Battery System

(charging mode)

AutoClutch

(engaged or

disengaged)

Inverter & Power Panel

(off)

PTO

Pump

(off)

Direct Hybrid - Regenerative Braking Mode

Engine

Torque

Regenerative

Torque

Inertial

Torque

Regen Trq = Inertial Trq

x Gear Ratio

Utility ---- Engine Off Electric PTO Mode

Utility Tools

(on)

Engine

(off)

Motor

(on)

AutoShift (AMT)

(in neutral)

Battery System

(discharging mode)

AutoClutch

(disengaged)

No Drive

Torque

Auxiliary Power Generator (APG)

Inverter & Power Panel

(optional on - 5-10kW)

PTO

Pump

(on)

Direct Hybrid - Engine Off ePTO Mode & APG

Utility ---- Engine On Mechanical PTO Mode

Utility Tools

(on)

Engine

(on)

Motor

(off)

AutoShift (AMT)

(in neutral)

AutoClutch

(engaged)

No Drive

Torque

Inverter & Power Panel

(off)

PTO

Pump

(on)

Direct Hybrid - Engine On Mechanical PTO Mode

Engine

Torque

Battery System

(charging mode optional)

Utility ---- 5 kW Engine Off Power Generation

Engine

(off)

Motor

(on/off optional)

AutoShift (AMT)

(in neutral)

Battery System

(discharging mode)

AutoClutch

(disengaged)

No Drive

Torque

Inverter & Power Panel

(on ---- up to 5kW AC output)

PTO

Pump

(on/off optional)

Utility Tools

(on/off optional)

Direct Hybrid - Engine Off Power Generation Mode

© 2002 Eaton Corporation. All rights reserved.

HLA for Refuse 2009Robert Golin – Business Development Manager

Hybrid Power Systems – Eaton Vehicle Group

HEV and HHV Comparison

Hybrid hydraulic systems have much higher

power capabilities, for a shorter length of time.

In addition, they typically regenerate more

braking energy than hybrid electric systems.

Hybrid Drive Technology… Hydraulic Hybrids: What are they??

Parallel Hybrid (HLA system)

Attaches to existing driveline

Enhances engine power availability

Energy Regeneration features

20-30% fuel economy improvement+

Increases vehicle brake life by >50%

Significant productivity increase possible

Production start with Peterbilt: Sept. 2009

Suited to heavy start-stop drive cycle

Distinct HLA market segments e.g. refuse

Retro-fit opportunities

Series Hybrid

Replaces entire existing transmission.

Applicable to broad variety of duty cycles

Energy Regeneration, CVT, Engine off

50%+ fuel economy improvement

Increases vehicle brake life by >70%

Reduced emissions for NOx & CO2 through

optimizing engine loading and RPM.

Commercialization planned : 2011

Apply in Package delivery, tow-trucks, wide

variety of bus types.

Has to be installed at chassis build time only.

N2

High-pressure

Accumulator

Fluid Reservoir

Hydraulic

Pump/Motor

= Energy Flow

N2

High-pressure

Accumulator

Fluid Reservoir

Hydraulic

Pump/Motor

N2N2

High-pressure

Accumulator

Fluid Reservoir

Hydraulic

Pump/Motor

= Energy Flow

N2

High-pressure

Accumulator

Low-pressure

Energy Storage

Hydraulic

Pump

Hydraulic

Pump/Motor

= Energy Flow

N2

High-pressure

Accumulator

Low-pressure

Energy Storage

Hydraulic

Pump

Hydraulic

Pump/Motor N2

High-pressure

Accumulator

Low-pressure

Energy Storage

Hydraulic

Pump

Hydraulic

Pump/Motor

= Energy Flow

Parallel Hydraulic Hybrid Architecture

In a parallel hydraulic hybrid, the conventional vehicle driveline is supplemented by the addition of the hybrid system.

The system is best suited for vehicles that operate in stop and go duty cycles. (examples include refuse trucks)

The value proposition is provided by:

Improved fuel economy achieved through regeneration of braking energy

Lower maintenance costs. Brake life is increased 3-4 times.

Improved productivity (e.g., more refuse pickups per day).

Engine downsizing potential to further reduce fuel consumption w/out losing power

Fuel economy and emissions improvements of 20-30% and payback periods of 3 years or less are possible in vehicles that last 10 years.

HLA® System for Heavy Duty Trucks

N2

High-pressure

Accumulator

Fluid Reservoir

Hydraulic

Pump/Motor

= Energy Flow

N2

High-pressure

Accumulator

Fluid Reservoir

Hydraulic

Pump/Motor

N2N2

High-pressure

Accumulator

Fluid Reservoir

Hydraulic

Pump/Motor

= Energy Flow

The HLA System

The system is a parallel hydraulic regenerative braking system.

The system uses fluid force to brake by charging a high

pressure accumulator.

Energy recovered is normally wasted as heat during braking.

Recovered energy is efficiently stored and used to supplement

the engine’s power during acceleration, on-demand.

The system provides the greatest benefit when the vehicle’s

driving cycle involves stop and go driving.

It’s all about the brakes!

Aero Drag

Rolling

Resistance

Braking

The objective of a Hybrid System is to

store and re-use as much as possible

of this wasted energy

Refuse is a great application

How does the HLA System work?

Regeneration Mode

During braking, the vehicle’s kinetic

energy drives the pump/motor as a pump,

transferring hydraulic fluid from the low

pressure reservoir to the high pressure

accumulator. The fluid compresses

nitrogen gas in the accumulator and

pressurizes the system.

Launch Assist Mode

During acceleration, fluid in the high

pressure accumulator is metered out to

drive the pump/motor as a motor. The

system propels the vehicle by

transmitting torque to the driveshaft.

Class 8 Refuse Truck Test Data

• 28.5 Tonne ( 63,000lb ) GVW

• 315 hp engine

• 5-speed automatic transmission

• 30 metres ( 100ft ) between stops

Designed for flexibility…

Heavy Duty Applications

© 2007 Eaton Corporation. All rights reserved.

Drive shaft

Coupling

Pump/Motor

Transfer case

High-pressure

accumulator

Filter

Reservoir

Designed for flexibility…

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

System Specifications

10-year design life

Ambient operating temperature ranges

Full function range: -30°C to 50°C

Annual service:

Oil and filter (reservoir, transfer case)

Nitrogen level check and top-off as

required

Maximum rated pressure

345 Bar 5000 psi

System Oil Volume

79.8 L 21 gal

Typical peak power per cycle

130 kW 175 HP

Displacement: 15 in3

Maximum Flow: 130 gpm

Maximum Power: 380 hp

Maximum Pump Torque: 1000 lb-ft

Peak torque to driveline: 2550 lb-ft

Transfer Case Ratio: 2.55:1

Transfer Case Through-Torque: 16,000 lb-ft

System pressure: 5000 psi max

HLA speed limit: 3000 rpm

System weight 1300 lbs

CAN Communications SAE J1939

Hydraulic Energy Storage

KINETIC

ENERGY

(Speed)

STORED

ENERGY

STOP

Neutral

‘x’ MPH speed

Accumulator

EMPTY

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

Hydraulic Energy Storage

KINETIC

ENERGY

(Speed)

STORED

ENERGY

HYDRAULIC

BRAKING

STOP

Pumping

mode

Maximum energy

recovered

Accumulator

FILLS

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

KINETIC

ENERGY

(Speed)

STORED

ENERGY

FRICTION BRAKING

brings vehicle to STOP

STOP

Pumping

mode

Hydraulic Energy Storage

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

KINETIC

ENERGY

(Speed)

STORED

ENERGY

FRICTION

brake applied

STOP

Neutral

Hydraulic Energy Storage

Vehicle

STOPPED

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

KINETIC

ENERGY

(Speed)

STORED

ENERGY

STOP

Motor

mode

Hydraulic Energy Storage

Hydraulic

launch assist

acceleration

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

KINETIC

ENERGY

(Speed)

STORED

ENERGY

ENGINE

ACCELERATION

STOP

Neutral

Hydraulic Energy Storage

System ready for next BRAKING

event

Power SystemsHybrid

© 2007 Eaton Corporation. All rights reserved.

In-Cab Information.

© 2007 Eaton Corporation. All rights reserved.

Fault Code:

State of Charge:

Service lights:

Service

Level

LED

LightResult Operator Actions

StopBlinking

Yellow

HLA system is

functioning

improperly

Stop vehicle and do not

drive. Record fault

number. Call for Service

ServiceContinuous

YellowHLA system

disabled

The vehicle may be used.

Record fault number.

Notify service.

OperateNo Service

light, No

Stop light

Normal System Ready

Service

Level

Service

Level

Service

Level

LED

Light

LED

Light

LED

LightResultResultResult Operator ActionsOperator ActionsOperator Actions

StopStopBlinking

Yellow

Blinking

Yellow

HLA system is

functioning

improperly

HLA system is

functioning

improperly

Stop vehicle and do not

drive. Record fault

number. Call for Service

Stop vehicle and do not

drive. Record fault

number. Call for Service

ServiceServiceContinuous

Yellow

Continuous

YellowHLA system

disabled

HLA system

disabled

The vehicle may be used.

Record fault number.

Notify service.

The vehicle may be used.

Record fault number.

Notify service.

OperateOperateNo Service

light, No

Stop light

No Service

light, No

Stop light

NormalNormal System ReadySystem Ready

Current Status:

Eaton began delivering a fleet of refuse trucks with pre-

production HLA systems to end users in December 2007.

These vehicles are used in refuse collection service for

for a one year test period.

Eaton is releasing the HLA system for use in Peterbilt

320 refuse chassis in Sept. 2009.

© 2002 Eaton Corporation. All rights reserved.

Jean-Claude Montpellier

514-386-5189

Francois Bourbeau

514-386-1343